Ultra stable cementitious material formulation, process for its making, and ultra stable tile backer board formulation and processes for its making

ABSTRACT

An ultrastable cementitious material with nano-molecular veneer makes a cementitious material by blending 29 wt % to 40 wt % of a magnesium oxide dry powder containing 80 wt % to 98 wt % of magnesium oxide based on a final total weight of the cementitious material, with 14 wt % to 18 wt % of a magnesium chloride dissolved in water and reacting to form a liquid suspension, mixing from 2 to 10 minutes, adding a phosphorus-containing material, and allowing the liquid suspension to react into an amorphous phase cementitious material, wherein a portion of the amorphous phase cementitious material grows a plurality of crystals. The plurality of crystals are encapsulated by the amorphous phase cementitious material forming a nano-molecular veneer. A process to make the ultrastable cementitious material. A tile backer board incorporating the ultrastable cementitious material and a process for making the tile backer board.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. Nonprovisional patentapplication Ser. No. 16/006,583, filed Jun. 12, 2018 entitled“Ultra-Stable Cementitious Construction Material Formulation”(2219.003A), which claims priority to and the benefit of U.S.Provisional Patent Application Ser. No. 62/582,517, filed on Nov. 7,2017 (2219.002), and U.S. Provisional Patent Application Ser. No.62/582,545 filed on Nov. 7, 2017 (2219.003). These applications areincorporated by reference herein in their entirety for all relevantpurposes.

This application is a Continuation of U.S. Nonprovisional patentapplication Ser. No. 16/006,598, filed Jun. 12, 2018 entitled “Processfor Making Ultra-Stable Cementitious Construction Material” (2219.003B),which claims priority to and the benefit of U.S. Provisional PatentApplication Ser. No. 62/582,517, filed on Nov. 7, 2017 (2219.002), andU.S. Provisional Patent Application Ser. No. 62/582,545 filed on Nov. 7,2017 (2219.003). These applications are incorporated by reference hereinin their entirety for all relevant purposes.

This application is a Continuation of U.S. Nonprovisional patentapplication Ser. No. 16/006,554, filed Jun. 12, 2018 entitled“Ultra-Stable Tile Backer Board Formulation” (2219.002A), which claimspriority to and the benefit of U.S. Provisional Patent Application Ser.No. 62/582,517, filed on Nov. 7, 2017 (2219.002), and U.S. ProvisionalPatent Application Ser. No. 62/582,545 filed on Nov. 7, 2017 (2219.003).These applications are incorporated by reference herein in theirentirety for all relevant purposes.

This application is a Continuation of U.S. Nonprovisional patentapplication Ser. No. 16/006,570, filed Jun. 12, 2018 entitled “Processfor Making Ultra-Stable Tile Backer Board” (2219.002B), which claimspriority to and the benefit of U.S. Provisional Patent Application Ser.No. 62/582,517, filed on Nov. 7, 2017 (2219.002), and U.S. ProvisionalPatent Application Ser. No. 62/582,545 filed on Nov. 7, 2017 (2219.003).These applications are incorporated by reference herein in theirentirety for all relevant purposes.

FIELD

The present invention generally relates to a formulation for making anultra-stable cementitious material, a process for its making, anultra-stable tile backer board formulation, and a process for making thetile backer board.

BACKGROUND

A need exists for a crystalline silica-free construction material withstructural integrity, fire-resistance, excellent insulation propertiesand superior resistance to mold, mildew, and termites.

A further need exists for a construction material with high hot waterstability.

The present embodiments meet these needs.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description will be better understood in conjunction withthe accompanying drawings as follows:

FIGS. 1A-1D depict the stepwise process for making the ultra-stablecementitious material and tile backer board of the present invention.

FIG. 2 depicts the X-ray diffraction pre-treatment and post-treatment ofmagnesium oxychloride with phosphoric acid.

FIGS. 3A-3H depict tables of cementitious material formulations of thepresent invention containing reinforcing components and aggregate andother additives along with physical properties of the formulations.

FIGS. 3I-3T depict tables of tile backer boards of the present inventioncontaining reinforcing components and aggregate and other additivesalong with physical properties of the formulations.

FIG. 4 is a table showing various additional formulations made accordingto the process of the present invention.

The present embodiments are detailed below with reference to the listedFigures.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Before explaining the present process in detail, it is to be understoodthat the formulation and process of the present invention are notlimited to the particular embodiments and that they can be practiced orcarried out in various ways.

The invention relates to a process for making an ultra-stablecementitious construction material consisting of a crystallized portionwith an amorphous nano-molecular veneer substantially free ofcrystalline silica.

The first step of the process involves forming a gel phase by blendingtogether magnesium oxide and magnesium chloride in a water with a weightratio of from 1.9:1 to 2.1:1 of magnesium oxide to magnesium chloride.

In the process, from 2 weight percent to 30 weight percent of aggregateis added to the gel phase, forming an amorphous phase.

Phosphorous acid or phosphoric acid or both are then added to theamorphous phase, actuating crystallization of a portion of the amorphousphase, while simultaneously forming a nano-molecular veneerencapsulating the crystallized portion of the amorphous phase withoutdetectable magnesium phosphate and with from 2% to 49% (e.g., 35% to49%) increase in surface area as compared to veneer-free crystallizedportions, and wherein the crystallized portion with nano-molecularveneer is configured to resist degradation in water having a temperatureat 60 degrees C. for 48 hours.

Benefits of the process are as follows: increased cement stability whensubmerged in water at temperatures up to 60 degrees C.; a physicalproperty that determines warm water stability for the above cement andno additional time required for this invention.

Benefits of the cementitious material formulation include increasedcement stability when submerged in water at temperatures up to 60degrees C.

The invention provides magnesium oxychloride cement that has increasedstability in environments with high temperatures and high moisture.

The invention provides a cementitious material with a protective layerthat is not an exposed crystal, so it is not susceptible to moisture orwater dissolving at elevated temperatures.

The invention stabilizes the concrete thereby reducing the corrosioneffects on other building materials in the assembly.

This invention has an improved water tolerance over other types ofmagnesium oxychloride cements without adding polymers or other sealantsthat can sacrifice some of the excellent fire-resistant properties ofmagnesium oxychloride cements.

The inventive and unexpected amorphous layer that protects the magnesiumoxychloride cement crystals is less detrimental to the structuralstrength of the cement product than other uses of phosphoric compoundshave proven to be.

The invention relates to a process for making a cementitiousconstruction material consisting of a crystallized portion with anamorphous nano-molecular veneer substantially free of crystallinesilica.

The first step of the process involves forming a gel phase by blendingtogether magnesium oxide and magnesium chloride in a water with a weightratio of from 1.9:1 to 2.1:1 of magnesium oxide to magnesium chloride.

In the process, from 2 weight percent to 30 weight percent of aggregateis added to the gel phase, forming an amorphous phase.

Phosphorous acid or phosphoric acid or both are then added to theamorphous phase, actuating crystallization of a portion of the amorphousphase, while simultaneously forming a nano-molecular veneerencapsulating the crystallized portion of the amorphous phase withoutdetectable magnesium phosphate and with from 2% to 49% increase insurface area as compared to veneer-free crystallized portions, andwherein the crystallized portion with nano-molecular veneer isconfigured to resist degradation in water having a temperature at 60degrees C. for 48 hours.

Benefits of the process are as follows: increased cement stability whensubmerged in water at temperatures up to 60 degrees C., a physicalproperty that determines warm water stability for the above cement, andno additional time required for this invention.

The invention relates to a process to make an ultrastable cementitiousmaterial with nano-molecular veneer and an ultrastable cementitiousmaterial with nano-molecular veneer.

The invention further relates to the formulation of a tile backer boardconsisting of a crystallized portion with an amorphous nano-molecularveneer substantially free of crystalline silica.

Benefits of the tile backer board formulation include increased cementstability when submerged in water at temperatures up to 60 degrees C.

The invention provides a tile backer board with a protective layer thatis not an exposed crystal, so it is not susceptible to moisture or waterdissolving at elevated temperatures.

The following definitions are used herein:

The term “aggregate” refers to a wood, perlite, foam beams, glass,calcium carbonate powder, or carbon fiber strands with a particle sizeno larger than 3 mm.

The term “amorphous phase” refers to a non-crystalline mixture of thefinal reacted products.

The term “amorphous nano-molecular veneer” refers to a coating bonded tothe crystallized portion that has a material which is not visible ascrystalline in an X-ray diffraction test, and has a density of moleculeswhich is inert to water molecules.

The term “biomass” refers to organic materials such as wood flour,straw, ground pecan shells, and ground up bagasse.

The term “cementitious construction material” refers to a board orstructure that is used for structural assembly to form facilities,offices, barns, homes, fences, and marine quarters for use on a ship oroil platform offshore.

The term “crystallized portion” refers to a segment of the createdcementitious construction material with activation energies of 70kilojoules per mole, having a monoclinic crystalline structure which inthis invention includes magnesium oxychloride.

The term “crystalline silica” refers to silica molecules, such as sand,in a crystalline phase, similar to glass.

The term “dispersible polymer” is a water dispersible ethylene-vinylacetate copolymer.

The term “encapsulating” refers to the creation of a nano-molecularveneer over surfaces of the crystals wherein the surface coating can beconnected, such as sandpaper which comprises many silica particlesadhered to a substrate with very little space between the silicaparticles. The dendritic nature of the plurality of crystals provide acoating that may be continuous or have small gaps.

The term “fibers” refers to needle-like materials that do not exceed 3mm in length, but could include longer fibers woven into a mat.

The term “gel phase” refers to a phase in which molecules attract toeach other without bonding in a slurry.

The term “insoluble in water” refers to a compound that will not go intosolution or degrade when exposed to water between ambient temperatureand 60 degrees C. for 0 hours to 48 hours.

The term “magnesium chloride in a water” refers to a liquid containinganhydrous magnesium chloride salt such as a water containing ananhydrous magnesium chloride salt with from 20 to 35 weight percent saltin the water which can be distilled water, dirty water containingparticulates and non-volatile organic matter, or clean tap water.

The term “magnesium oxide” refers to the powder form of MgO with from80% to 98% purity, the balance being calcium carbonate, quartz, or ironoxide or similar impurities naturally found in magnesite.

The term “magnesium phosphate crystals” refers to the crystals formed bythe reaction of magnesium oxide with phosphoric acid or phosphorousacid.

The term “nano-molecular elements” refers to the newly identified,insoluble in water, non-crystalline, phosphorous-containing species;identifiable with scan electron microscope (SEM) with elementalanalysis. This material will not show up as a phosphorous containingspecies on XRAY DIFFRACTION.

The term “phosphoric acid” refers to a concentrate of H₃PO₄ with adensity of 1.1 g/ml to 1.85 g/ml.

The term “phosphorous acid” refers a concentrate of H₃PO₃ with a densityof 1.1 g/ml to 1.65 g/ml.

The term “plurality of crystals” refers to the magnesium oxychloridecrystals which form from part of the amorphous phase.

The term “predetermined temperature for the water” refers to atemperature from ambient temperature to 90 degrees C.”.

The term “preset period of time” refers to a window of time from 10hours to 90 hours, and specifically includes from 24 hours to 72 hours.

The phrase “protects the plurality of crystals from degradation inwater” refers to the nano-molecular veneer making the strength losslower than it would be without the nano-molecular veneer when thecementitious material is exposed to water between ambient temperatureand 60 degrees C. for 0-48 hours.

The term “substantially free” refers to a less than 3 weight percentcontent of crystalline silica based on x-ray diffraction testing in thecementitious construction material.

The term “surface area” refers to the surface area as tested using theBET theory methodology.

The term “veneer” refers to a chemically bonded protective layer on thecrystallized portion of the amorphous phase configured to resist waterwhich can be elevated to 60 degrees C. for extended periods of time.

The term “water” refers to H₂0with impurities of less than 0.5 weightpercent.

Process for Making Ultra-Stable Cementitious Material

A process to make an ultrastable cementitious material with nano-veneerinvolves blending 29 wt % to 40 wt % of a magnesium oxide dry powdercontaining 80 wt % to 98 wt % of magnesium oxide based on a final totalweight of the cementitious material, with 14 wt % to 18 wt % of amagnesium chloride dissolved in water based on a final total weight ofthe cementitious material.

The magnesium oxide has a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles are less than or equal to about 40 microns.

The magnesium chloride is in an aqueous solution. The magnesium chloridecan be a 20 wt % to 30 wt % a magnesium chloride aqueous solution.

The magnesium oxide and the magnesium chloride in water, react to form aliquid suspension.

The process involves mixing the liquid suspension for from 2 minutes to10 minutes while minimizing adding gas into the liquid suspension.

The process involves adding 0.1 wt % to 10 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

The stabilizing material with the phosphorus-containing compound can bea phosphorous acid (A) based on the final total weight of thecementitious material, wherein the phosphorous acid consists of anaqueous solution of 55 wt % to 65 wt % of a concentrate of H₃PO₃; or aphosphoric acid (B) based on the final total weight of the cementitiousmaterial, wherein the phosphoric acid consists of an aqueous solution of80 wt % to 90 wt % of a concentrate of H₃PO₄.

The next step of the process allowing the liquid suspension withstabilizing material to react into an amorphous phase cementitiousmaterial for a period of time from 1 minute to 4 minutes.

A portion of the amorphous phase cementitious material grows a pluralityof crystals, each crystal having a MW within the range of 280 to 709,the amorphous phase cementitious material encapsulating the plurality ofcrystals, wherein a majority of stabilizing material with aphosphorus-containing compound are consumed into a nano-molecular veneerwhile increasing surface area of the plurality of crystals by 2% to 49%during curing, and wherein the nano-molecular elements of the curednano-molecular veneer are insoluble in water and the curednano-molecular veneer protects the plurality of crystals fromdegradation in water at temperatures from 20 degrees to 60 degreesCelsius for from 24 hours to 56 days of the formed cementitiousmaterial.

In an embodiment, the process involves blending 35 wt % to 79.9 wt % ofthe formed cementitious material with 0.1 wt % to 30 wt % of anaggregate based on a final total weight of the concrete, the aggregatecomprising particles, having a diameter from 1 nm to 10 mm, wherein theaggregate comprises at least one of: wood, perlite, styrene based foambeads, calcium carbonate powder, glass particulate, and combinationsthereof.

In an embodiment, the process involves pouring the concrete over 0.1 wt% to 2 wt % of a reinforcing material based on a final total weight ofthe cementitious material that cures into the cementitious material, thereinforcing material comprising a non-woven or woven silica containingmat, a non-woven or woven hydrocarbon containing mat.

In an embodiment, the process involves adding 0.1 weight percent to 15weight percent biomass added to the amorphous phase cementitiousmaterial based on the final total weight of the concrete and mixing from3 to 10 minutes.

The biomass can be a member of the group: rice husks, corn husks, anddung.

In an embodiment, the process involves adding 0.1 wt % to 10 wt % of atleast one surfactant to the cementitious material based on the finaltotal weight of the concrete to decrease porosity of aggregate andprevent amorphous phase cementitious material from entering pores of theaggregate.

The surfactant can be a detergent.

In an embodiment, the process involves adding 0.1 weight percent to 5weight percent of a re-dispersible powder polymer based on the finaltotal weight of the concrete and mixing from 3 to 10 minutes.

In an embodiment, the re-dispersible powder polymer can be selected fromthe group consisting of silicon, polyurethane dispersion, polyurethane,alkyl carboxylic acid vinyl ester monomer, branched and unbranchedalcohol(meth)acrylic acid ester monomer, vinyl aromatic monomer, olefinmonomer, diene monomer and vinyl halide monomer or a vinyl acetateethylene “VAE”.

In an embodiment, the process involves adding 0.1 weight percent to 5weight percent based on the final total weight of the cementitiousmaterial of an acrylic or styrene butadiene rubber (SBR) into theconcrete while the re-dispersible powder polymer is added.

In an embodiment, the process involves adding 0.1 wt % to 15 wt % of areinforcing material based on the final total weight of the concrete.

The reinforcing material can be at least one of: a chopped silicacontaining fibers; hemp containing fibers; nano-molecular carbon fiberstrands; chopped carbon fibers; chopped hydrocarbon fiber; andcombinations thereof;

Ultra-Stable Cementitious Material

The ultrastable cementitious material contains 29 wt % to 40 wt % of amagnesium oxide dry powder containing 80 wt % to 98 wt % of magnesiumoxide based on a final total weight of the cementitious material, themagnesium oxide with a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles are less than or equal to about 40 microns.

The ultrastable cementitious material contains 14 wt % to 18 wt % of amagnesium chloride dissolved in water based on a final total weight ofthe cementitious material.

The ultrastable cementitious material contains 0.1 wt % to 10 wt % of astabilizing material with a phosphorus-containing compound based on afinal total weight of the cementitious material.

The stabilizing material with the phosphorus-containing compound has aphosphorous acid (A) based on the final total weight of the cementitiousmaterial, wherein the phosphorous acid consists of an aqueous solutionof 55 wt % to 65 wt % of a concentrate of H₃PO₃; or a phosphoric acid(B) based on the final total weight of the cementitious material,wherein the phosphoric acid consists of an aqueous solution of 80 wt %to 90 wt % of a concentrate of H₃PO₄.

A portion of the amorphous phase cementitious material grows a pluralityof crystals, each crystal having a MW within the range of 280 to 709,the amorphous phase cementitious material encapsulating the plurality ofcrystals, wherein a majority of stabilizing material with aphosphorus-containing compound are consumed into a nano-molecular veneerwhile increasing surface area of the plurality of crystals by 2% to 49%during curing, and wherein the nano-molecular elements of the curednano-molecular veneer are insoluble in water and the curednano-molecular veneer protects the plurality of crystals fromdegradation in water at temperatures from 20 degrees to 60 degreesCelsius for from 24 hours to 56 days of the formed cementitiousmaterial.

In an embodiment, ultra-stable cementitious material with nano-molecularveneer includes: 0.1 wt % to 30 wt % of an aggregate based on a finaltotal weight of the concrete, the aggregate comprising particles, havinga diameter from 1 nm to 10 mm, wherein the aggregate comprises at leastone of: wood, perlite, styrene based foam beads, calcium carbonatepowder, glass particulate, and combinations thereof.

In an embodiment, ultra-stable cementitious material with nano-molecularveneer includes: 0.1 wt % to 2 wt % of a reinforcing material based on afinal total weight of the cementitious material, the reinforcingmaterial comprising a non-woven or woven silica containing mat, anon-woven or woven hydrocarbon containing mat.

In an embodiment, ultra-stable cementitious material with nano-molecularveneer includes: 0.1 weight percent to 15 weight percent biomass addedto the amorphous phase cementitious material based on the final totalweight of the concrete.

The biomass can be a member of the group comprising: rice husks, cornhusks, and dung.

In an embodiment, ultra-stable cementitious material with nano-molecularveneer includes: 0.1 wt % to 10 wt % of at least one surfactant to thecementitious material based on the final total weight of the concrete todecrease porosity of aggregate and prevent amorphous phase cementitiousmaterial from entering pores of the aggregate.

The surfactant can be a detergent.

In an embodiment, ultra-stable cementitious material with nano-molecularveneer includes: 0.1 weight percent to 5 weight percent of are-dispersible powder polymer based on the final total weight of theconcrete.

The re-dispersible powder polymer is selected from the group consistingof silicon, polyurethane dispersion, polyurethane, alkyl carboxylic acidvinyl ester monomer, branched and unbranched alcohol(meth)acrylic acidester monomer, vinyl aromatic monomer, olefin monomer, diene monomer andvinyl halide monomer or a vinyl acetate ethylene “VAE”.

In an embodiment, ultra-stable cementitious material with nano-molecularveneer includes: 0.1 weight percent to 5 weight percent based on thefinal total weight of the cementitious material of an acrylic or styrenebutadiene rubber (SBR) into the concrete while the re-dispersible powderpolymer is added.

In an embodiment, ultra-stable cementitious material with nano-molecularveneer includes: 0.1 wt % to 15 wt % of a reinforcing material based onthe final total weight of the concrete.

The reinforcing material comprising at least one of: chopped silicacontaining fibers; hemp containing fibers; nano-molecular carbon fiberstrands; chopped carbon fibers; chopped hydrocarbon fiber; andcombinations thereof.

The aggregate includes particles based on a final total weight of thecementitious material, having a diameter from 1 nm to 10 mm.

The aggregate contains at least one of: wood, perlite, styrene basedfoam beads, calcium carbonate powder, glass particulate, andcombinations thereof.

The cementitious material with aggregate is blended to the amorphousphase with from 0.1 wt % to 2 wt % of a reinforcing material based on afinal total weight of the cementitious material.

The reinforcing material can be a non-woven or woven silica containingmat, a non-woven, or woven hydrocarbon containing mat.

In other embodiments, the reinforcing material can be chopped silicacontaining fibers; hemp containing fibers; nano-molecular carbon fiberstrands; chopped carbon fibers; chopped hydrocarbon fiber; andcombinations thereof.

The amorphous phase cementitious material containing aggregate can bepoured over the reinforcing material enabling a portion of the amorphousphase cementitious material to grow a plurality of crystals, eachcrystal having a MW within the range of 280 to 709, the amorphous phasecementitious material encapsulating the plurality of crystals.

A majority of stabilizing material with a phosphorus-containing compoundcan be consumed into a nano-molecular veneer while increasing surfacearea of the plurality of crystals by 2% to 49% during curing, andwherein the nano-molecular elements of the cured nano-molecular veneerare insoluble in water and the cured nano-molecular veneer protects theplurality of crystals from degradation in water at temperatures from 20degrees to 60 degrees Celsius for from 24 hours to 56 days of the formedcementitious material.

In embodiments of the cementitious material, 0.1 weight percent to 15weight percent biomass can be added to the amorphous phase cementitiousmaterial based on the final total weight of the cementitious material.

In embodiments of the cementitious material, 0.1 wt % to 10 wt % of atleast one surfactant is added to the cementitious material based on thefinal total weight of the cementitious material to decrease porosity ofaggregate and prevent amorphous phase cementitious material fromentering pores of the aggregate.

In embodiments of the cementitious material, 0.1 weight percent to 5weight percent of a re-dispersible powder polymer based on the finaltotal weight of the cementitious material can be incorporated in theamorphous phase cementitious material.

In embodiments of the cementitious material, the re-dispersible powderpolymer can be selected from the group consisting of acrylic, silicon,polyurethane dispersion, polyurethane, alkyl carboxylic acid vinyl estermonomer, branched and unbranched alcohol(meth)acrylic acid estermonomer, vinyl aromatic monomer, olefin monomer, diene monomer and vinylhalide monomer.

In embodiments of the cementitious material, 0.1 weight percent to 5weight percent based on the final total weight of the cementitiousmaterial of an acrylic or styrene butadiene rubber (SBR) can be blendedinto the amorphous cementitious material with the re-dispersible powderpolymer.

In embodiments of the cementitious material, 0.1 weight percent to 5weight percent based on the final total weight of the cementitiousmaterial of a re-dispersible polymer powder can be added to theamorphous cementitious material, wherein the re-dispersible polymerpowder is a member of the group consisting of: a vinyl ethylene esterand ethylene, a vinyl laurate vinyl chloride copolymer, a vinyl estermonomers, (meth)acrylate monomer, a vinyl aromatic monomer, an olefinmonomer, a 1,3-diene monomer, a vinyl halide monomer, a homopolymer orcopolymer derived from one or more monomers selected from the groupconsisting of a vinyl acetate, a vinyl ester of an alpha-branchedmonocarboxylic acids having from 9 to 11 carbon atoms, a vinyl chloride,an ethylene, a methyl acrylate, a methyl methacrylate, an ethylacrylate, an ethyl methacrylate, a propyl acrylate, a propylmethacrylate, an n-butyl acrylate, a n-butyl methacrylate, an2-ethylhexyl acrylate.

The invention relates to a building with an exterior building surfacecovered with the cementitious material of the formulations of theindependent claims of this application.

FIG. 1A shows the steps of the invention.

The process for making a cementitious construction material as step 100:forming a gel phase by blending together magnesium oxide and magnesiumchloride in water.

Step 110 can involve adding at least one of: a phosphorous acid and aphosphoric acid to the gel phase while forming an amorphous phase.

Step 120 can require adding from 2 weight percent to 30 weight percentof aggregate to the amorphous phase based on a total final weight of thecementitious construction material.

Step 130 can involve crystallizing a portion of the amorphous phase intoa plurality of crystals generating nano-molecular elements that projectfrom the plurality of crystals, encapsulating the plurality of crystals,forming a nano-molecular veneer without detectable magnesium phosphatecrystals while increasing surface area of the plurality of crystals by2% to 49%, and wherein the nano-molecular elements of the nano-molecularveneer are insoluble in water and the nano-molecular veneer protects theplurality of crystals from degradation in water at a predeterminedtemperature for a preset period of time.

In embodiments, the process for making a cementitious constructionmaterial can include adding from 0.1 weight percent to 15 weight percentbiomass to the gel phase based on the total final weight of thecementitious construction material.

In embodiments, the process for making a cementitious constructionmaterial can involve adding from 0.1 weight percent to 5 weight percentof a dispersible polymer to the gel phase based on the total finalweight of the cementitious construction material.

FIG. 1B depicts the steps needed to make the tile backer board.

Step 200 can include forming from 35 wt % to 79.9 wt % of a cementitiousmaterial based on the final total weight of the tile backer board.

Step 201 can involve blending from 29 wt % to 40 wt % of a magnesiumoxide dry powder containing 80 wt % to 98 wt % of magnesium oxide basedon a final total weight of the cementitious material into 14 wt % to 18wt % of a magnesium chloride dissolved in water based on a final totalweight of the cementitious material.

Step 202 can involve mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water forming a liquid suspension whileminimizing adding gas into the liquid suspension.

Step 204 can involve adding from 0.1 wt % to 10 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

Step 206 can involve reacting during a preset unit of time, the mixedliquid suspension into an amorphous phase cementitious material.

Step 208 can involve blending to the amorphous phase cementitiousmaterial from 0.1 wt % to 30 wt % of an aggregate comprising particlesbased on a final total weight of the tile backer board, having adiameter from 1 nm to 10 mm, wherein the aggregate comprises at leastone of: wood, perlite, styrene based foam beads, calcium carbonatepowder, glass particulate, and combinations thereof.

Step 210 can involve pouring the flowable concrete over from 0.1 wt % to2 wt % of a reinforcing material based on a final total weight of thetile backer board forming a reinforced concrete.

Step 212 can involve forming during a preset unit of time, in a portionof the amorphous phase cementitious material a plurality of crystals ofa defined Molecular Weight from the amorphous non-crystallinenano-molecular cementitious material encapsulating the plurality ofcrystals, creating a nano-molecular veneer without detectablephosphorus-containing compound while increasing surface area of theplurality of crystals.

Step 214 can include testing the formed tile backer board for stabilityin water at 60 degrees Celsius for 24 hours using the Jet Products, LLCWarm Water Stability Test as authenticated by Clemson UniversityChemical Engineering Department in 2017.

FIG. 1C depicts additional steps to be used with the embodiment of FIG.1A to make the cementitious material.

FIG. 1C depicts:

Step 220 can include adding from 0.1 wt % to 15 wt % biomass to theamorphous phase cementitious material based on the final total weight ofthe tile backer board.

Step 222 can include adding from 0.1 wt % to 10 wt % of at least onesurfactant which is added to the cementitious material based on thefinal total weight of the tile backer board to decrease porosity ofaggregate and prevent amorphous phase cementitious material fromentering pores of the aggregate.

Step 224 can include adding from 0.1 weight percent to 5 weight percentof a re-dispersible powder polymer based on the final total weight ofthe tile backer board into the amorphous phase cementitious material.

Step 226 can include blending from 0.1 weight percent to 5 weightpercent of an acrylic or styrene butadiene rubber (SBR) based on thefinal total weight of the tile backer board into the amorphouscementitious material with the re-dispersible powder polymer.

FIG. 1D shows steps of another embodiment to make the cementitiousmaterial.

Step 250 can include forming from 55 wt % to 99.8 wt % of a cementitiousmaterial based on the final total weight of the tile backer board.

Step 252 can include forming from 55 wt % to 99.8 wt % of a cementitiousmaterial by blending 29 wt % to 40 wt % of a magnesium oxide dry powdercontaining from 80 wt % to 98 wt % of magnesium oxide based on a finaltotal weight of the based on the cementitious material with from 14 wt %of 18 wt % of a magnesium chloride dissolved in water based on based onthe final total weight of the cementitious material, to form a liquidsuspension.

Step 254 can involve adding from 0.1 wt % to 10 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the liquid suspension.

Step 256 can include allowing the liquid suspension to react into anamorphous phase cementitious material during a preset period of time.

Step 258 can involve adding from 0.1 wt % to 30 wt % of an aggregatebased on the total weight of the tile backer board to the amorphousphase cementitious material.

Step 260 can involve adding from 0.1 wt % to 15 wt % of a reinforcingmaterial based on the final total weight of the tile backer board, tothe amorphous phase cementitious material, wherein the reinforcingmaterial is at least one of: chopped silica containing fibers; hempcontaining fibers; nano-molecular carbon fiber strands; chopped carbonfibers; chopped hydrocarbon fiber; and combinations thereof.

Step 262 can involve growing a portion of the amorphous phasecementitious material grows a plurality of crystals, each crystal havinga MW within the range of 283 to 709, the amorphous phase cementitiousmaterial encapsulating the plurality of crystals, wherein a majority ofstabilizing material with a phosphorus-containing compound are consumedinto a nano-molecular veneer while increasing surface area of theplurality of crystals by 2% to 49% during curing, and wherein thenano-molecular elements of the cured nano-molecular veneer are insolublein water and the cured nano-molecular veneer protects the plurality ofcrystals from degradation in water at temperatures from 20 degrees to 60degrees Celsius for from 24 hours to 56 days of the formed tile backerboard.

In embodiments, the cementitious construction material can create anano-molecular veneer with a thickness from 1 micron to 3 microns.

In embodiments, the cementitious construction material can be used tocreate a cementitious construction material configured to support a loadof at least 2.5 pounds per square foot.

In embodiments, the cementitious construction material produces productcan be used to create a home, an office, a warehouse, a shed, a dock,artwork, aqueducts, or another load supporting structure.

In embodiments, the water can be a brine or similar salt solution with aconcentration of 2% to 30% salt.

In embodiments, the cementitious construction material can containfibers.

In variations of the cementitious construction material, prior tocrystallizing the amorphous phase, an additional substrate can beintroduced and coated with the cementitious construction material havingoriented strand board, plywood, waterproof membrane, concrete, and wood,and coated with the amorphous phase increasing fire resistance andstability in hot water.

The cementitious construction material can include least one surfactantadded to the amorphous phase to decrease porosity of aggregates andprevent amorphous phase from entering pores of the aggregates.

The surfactants can be any molecule that reduces the surface porosity ofthe aggregates being used in the cement.

In embodiments, the amorphous phase can be crystallized using atemperature from 40 to 50 degrees C. for a period of time from 3 to 24hours, at a relative humidity from 30 to 100 percent.

In embodiments, the cementitious construction material can be formedusing an exothermic reaction, such as generating 10 to 15 degrees ofheat for the duration of the reaction.

In embodiments, the cementitious construction material gel phase can beformed using intimate mixing for at least 3 minutes prior to addingaggregate.

FIG. 2 shows diffractograms of cured samples produced from X-raydiffraction at 28 degrees C. The major 5 phase peaks are labelled. Thefour upper quadrants are post phosphoric acid treatment and the bottomquadrant is pre phosphoric acid treatment.

The importance of this FIG. 2 is the area under the peaks.

Tile Backer Board

The invention relates to a tile backer board formulation.

The tile backer board can be formed from 35 wt % to 79.9 wt % of acementitious material based on a final total weight of the tile backerboard.

The cementitious material can be made from 29 wt % to 40 wt % of amagnesium oxide dry powder containing 80 wt % to 98 wt % of magnesiumoxide based on a final total weight of the cementitious material.

The magnesium oxide can have a surface area ranging from 5 meters²/gramto 50 meters²/gram and an average particle size ranging from about 0.3microns to about 90 microns, wherein more than about 90% by weightmagnesium oxide particles are less than or equal to about 40 microns.

The cementitious material can be made by mixing 14 wt % of 18 wt % of amagnesium chloride dissolved in water based on a final total weight ofthe cementitious material with the magnesium oxide dry powder.

The magnesium chloride in aqueous solution can have from 20 wt % to 30wt % of a magnesium chloride aqueous solution, wherein the magnesiumoxide and the magnesium chloride in water, react to form a liquidsuspension.

The cementitious material can include from 0.1 wt % to 10 wt % of astabilizing material with a phosphorus-containing compound based on afinal total weight of the cementitious material.

When mixed with the liquid suspension, the mixture reacts into anamorphous phase cementitious material.

The stabilizing material with the phosphorus-containing compound can bea phosphorous acid (A) based on the final total weight of thecementitious material, wherein the phosphorous acid consists of anaqueous solution of 55 wt % to 65 wt % of a concentrate of H₃PO₃; or aphosphoric acid (B) based on the final total weight of the cementitiousmaterial, wherein the phosphoric acid consists of an aqueous solution of80 wt % to 90 wt % of a concentrate of H₃PO₄.

The cementitious material is blended from 0.1 wt % to 30 wt % of anaggregate to the amorphous phase.

The aggregate can include particles based on a final total weight of thetile backer board, having a diameter from 1 nm to 10 mm.

The aggregate can contain at least one of: wood, perlite, styrene basedfoam beads, calcium carbonate powder, glass particulate, andcombinations thereof.

The cementitious material with aggregate is blended from 0.1 wt % to 2wt % of a reinforcing material based on a final total weight of the tilebacker board to the amorphous phase.

The reinforcing material can be a non-woven or woven silica containingmat, a non-woven or woven hydrocarbon containing mat.

In other embodiments, the reinforcing material can be chopped silicacontaining fibers, hemp containing fibers, nano-molecular carbon fiberstrands, chopped carbon fibers, chopped hydrocarbon fiber, andcombinations thereof.

The amorphous phase cementitious material containing aggregate is pouredover the reinforcing material enabling a portion of the amorphous phasecementitious material to grow a plurality of crystals, each crystal canhave a MW within the range of from 280 to 709, the amorphous phasecementitious material encapsulating the plurality of crystals.

A majority of stabilizing material with a phosphorus-containing compoundcan be consumed into a nano-molecular veneer while increasing surfacearea of the plurality of crystals by 2% to 49% during curing, andwherein the nano-molecular elements of the cured nano-molecular veneerare insoluble in water and the cured nano-molecular veneer protects theplurality of crystals from degradation in water at temperatures from 20degrees to 60 degrees Celsius for from 24 hours to 56 days of the formedtile backer board.

In embodiments of the tile backer board, 0.1 weight percent to 15 weightpercent biomass is added to the amorphous phase cementitious materialbased on the final total weight of the tile backer board.

In embodiments of the tile backer board, 0.1 wt % to 10 wt % of at leastone surfactant is added to the cementitious material based on the finaltotal weight of the tile backer board to decrease porosity of aggregateand prevent amorphous phase cementitious material from entering pores ofthe aggregate.

In embodiments of the tile backer board, 0.1 weight percent to 5 weightpercent of a re-dispersible powder polymer based on the final totalweight of the tile backer board can be incorporated in the amorphousphase cementitious material.

In embodiments of the tile backer board, the re-dispersible powderpolymer can be selected from the group consisting of acrylic, silicon,polyurethane dispersion, polyurethane, alkyl carboxylic acid vinyl estermonomer, branched and unbranched alcohol(meth)acrylic acid estermonomer, vinyl aromatic monomer, olefin monomer, diene monomer and vinylhalide monomer.

In embodiments of the tile backer board, 0.1 weight percent to 5 weightpercent based on the final total weight of the tile backer board of anacrylic or styrene butadiene rubber (SBR) can be blended into theamorphous cementitious material with the re-dispersible powder polymer.

In embodiments of the tile backer board, 0.1 weight percent to 5 weightpercent based on the final total weight of the tile backer board of are-dispersible polymer powder can be added to the amorphous cementitiousmaterial, wherein the re-dispersible polymer powder is a member of thegroup consisting of: a vinyl ethylene ester and ethylene, a vinyllaurate vinyl chloride copolymer, a vinyl ester monomers, (meth)acrylatemonomer, a vinyl aromatic monomer, an olefin monomer, a 1,3-dienemonomer, a vinyl halide monomer, a homopolymer or copolymer derived fromone or more monomers selected from the group consisting of a vinylacetate, a vinyl ester of an alpha-branched monocarboxylic acids havingfrom 9 to 11 carbon atoms, a vinyl chloride, an ethylene, a methylacrylate, a methyl methacrylate, an ethyl acrylate, an ethylmethacrylate, a propyl acrylate, a propyl methacrylate, an n-butylacrylate, a n-butyl methacrylate, an 2-ethylhexyl acrylate.

The invention relates to a building with an interior building surfacecovered with the tile backer board of the formulations of theindependent claims of this application.

Process for Making Tile Backer Board

The process involves blending 35 wt % to 79.9 wt % of the formedcementitious material based on a final total weight of the tile backerboard with 0.1 wt % to 30 wt % of an aggregate comprising particlesbased on a final total weight of the tile backer board, having adiameter from 1 nm to 10 mm, wherein the aggregate comprises at leastone of: wood, perlite, styrene based foam beads, calcium carbonatepowder, glass particulate, and combinations thereof forming a concrete.

The process continues by pouring the concrete over 0.1 wt % to 2 wt % ofa reinforcing material based on a final total weight of the tile backerboard that cures into the tile backer board, the reinforcing materialcomprising a non-woven or woven silica containing mat, a non-woven orwoven hydrocarbon containing mat.

A portion of the amorphous phase cementitious material grows a pluralityof crystals, each crystal having a MW within the range of 280 to 709,the amorphous phase cementitious material encapsulating the plurality ofcrystals, wherein a majority of stabilizing material with aphosphorus-containing compound are consumed into a nano-molecular veneerwhile increasing surface area of the plurality of crystals by 2% to 49%during curing, and wherein the nano-molecular elements of the curednano-molecular veneer are insoluble in water and the curednano-molecular veneer protects the plurality of crystals fromdegradation in water at temperatures from 20 degrees to 60 degreesCelsius for from 24 hours to 56 days of the formed tile backer board.

The process involves adding 0.1 weight percent to 15 weight percentbiomass added to the amorphous phase cementitious material based on thefinal total weight of the tile backer board and mixing from 3 to 10minutes.

The biomass is a member of the group comprising: rice husks, corn husks,and dung.

The process includes adding 0.1 wt % to 10 wt % of at least onesurfactant to the cementitious material based on the final total weightof the tile backer board to decrease porosity of aggregate and preventamorphous phase cementitious material from entering pores of theaggregate.

The surfactant can be a detergent.

The process can involves adding 0.1 weight percent to 5 weight percentof a re-dispersible powder polymer based on the final total weight ofthe tile backer board incorporated in the amorphous phase cementitiousmaterial and mixing from 3 to 10 minutes.

The re-dispersible powder polymer can be selected from the groupconsisting of silicon, polyurethane dispersion, polyurethane, alkylcarboxylic acid vinyl ester monomer, branched and unbranchedalcohol(meth)acrylic acid ester monomer, vinyl aromatic monomer, olefinmonomer, diene monomer and vinyl halide monomer or a vinyl acetateethylene “VAE”.

The process can include adding 0.1 weight percent to 5 weight percentbased on the final total weight of the tile backer board of an acrylicor styrene butadiene rubber (SBR) into the amorphous cementitiousmaterial while the re-dispersible powder polymer is added.

The invention includes an interior building surface covered with tilebacker board made by the process.

Another embodiment of the process for making a tile backer boardinvolves forming a cementitious material by blending 29 wt % to 40 wt %of a magnesium oxide dry powder containing 80 wt % to 98 wt % ofmagnesium oxide based on a final total weight of the based on thecementitious material with 14 wt % of 18 wt % of a magnesium chloridedissolved in water based on based on the final total weight of thecementitious material.

The magnesium oxide and the magnesium chloride in water, react to form aliquid suspension.

The next step involves mixing the liquid suspension for from 2 minutesto 10 minutes while minimizing adding gas into the liquid suspension,then adding 0.1 wt % to 10 wt % of a stabilizing material with aphosphorus-containing compound based on a final total weight of thecementitious material to the liquid suspension.

In this version of the process, the liquid suspension with stabilizingmaterial reacts into the amorphous phase cementitious material during aperiod of time from 1 minute to 4 minutes.

The process includes blending 35 wt % to 79.9 wt % of the formedamorphous phase cementitious material based on the final total weight ofthe tile backer board with 0.1 wt % to 30 wt % of an aggregate based onthe total weight of the tile backer board comprising particles having adiameter from 1 nm to 10 mm, wherein the aggregate comprises at leastone of, wood, perlite, styrene based foam beads, calcium carbonatepowder, and combinations thereof.

The next step involves mixing in 0.1 wt % to 15 wt % of a reinforcingmaterial based on the final total weight of the tile backer board, thereinforcing material comprising at least one of: chopped silicacontaining fibers, hemp containing fibers; nano-molecular carbon fiberstrands; chopped carbon fibers; chopped hydrocarbon fiber; andcombinations thereof.

A portion of the amorphous phase cementitious material grows a pluralityof crystals, each crystal having a MW within the range of 283 to 709,the amorphous phase cementitious material encapsulating the plurality ofcrystals, wherein a majority of stabilizing material with aphosphorus-containing compound are consumed into a nano-molecular veneerwhile increasing surface area of the plurality of crystals by 2% to 49%during curing, and wherein the nano-molecular elements of the curednano-molecular veneer are insoluble in water and the curednano-molecular veneer protects the plurality of crystals fromdegradation in water at temperatures from 20 degrees to 60 degreesCelsius for from 24 hours to 56 days of the formed tile backer board.

The process involves adding 0.1 weight percent to 15 weight percentbiomass which is added to the amorphous phase cementitious materialbased on the final total weight of the tile backer board, wherein thebiomass is a member of the group comprising: rice husks, corn husks, anddung.

EXAMPLES Example 1

A process to make a cementitious construction cementitious materialfollows:

The process produces a cementitious material with a 78% crystallizedportion with 12% of an amorphous nano-molecular veneer substantiallyfree of crystalline silica.

To create the cementitious material, first a gel phase is formed byblending together magnesium oxide powder with a purity of 85% by weightand a magnesium chloride in a brine with density of 1.26.

The magnesium oxide is blended in a weight ratio of 2:1 with themagnesium chloride based on the total final weight of the cementitiousconstruction material.

Next, from 20 weight percent of aggregate from wood is added to the gelphase forming the amorphous phase.

To the amorphous phase, 5 weight percent of phosphoric acid is addedbased on the total final weight of the cementitious constructionmaterial.

To complete forming of the cementitious material, 65% of the amorphousphase is crystalized by extruding the amorphous phase between two layersof fiberglass on a carrier sheet. The sandwich-like material is cured at45-55 degrees C. for 12-24 hours at a relative humidity greater than 55%creating a board with a thickness of 12 mm.

A nano-molecular veneer is formed over the crystallized portion with aveneer thickness of 1 micron encapsulating the portion of thecrystallized portion without producing detectable magnesium phosphate.The nano-molecular veneer has a 30% increase in surface area as comparedto veneer-free crystallized portions.

The final crystallized portion with nano-molecular veneer is configuredto resist degradation in water having a temperature at 60 degrees C. for48 hours.

Example 2

A cementitious material is formed with 70 wt % cementitious material.

The cementitious material has 34 wt % of a magnesium oxide dry powdercontaining 85 wt % purity of magnesium oxide based on a final totalweight of the cementitious material.

The novel cementitious material is formed by combining 34 wt % of amagnesium oxide dry powder containing 85 wt % purity of magnesium oxidebased on a final total weight of the cementitious material.

The magnesium oxide used has a surface area ranging from 5 meters²/gramto 50 meters²/gram and an average particle size ranging from about 0.3to about 90 microns wherein more than about 90% by weight magnesiumoxide particles are less than or equal to about 40 microns.

16 wt % of a magnesium chloride was dissolved in water based on a finaltotal weight of the cementitious material. The magnesium chloride inaqueous solution was: 29 wt % of a magnesium chloride aqueous solution.The magnesium oxide and the magnesium chloride in water reacted to forma liquid suspension.

1.3 wt % of a stabilizing material with a phosphorus-containing compoundbased on a final total weight of the cementitious material was thenmixed with the liquid suspension and the mixture reacted into anamorphous phase cementitious material.

The stabilizing material with the phosphorus-containing compound wasphosphoric acid (B) based on the final total weight of the cementitiousmaterial, wherein the phosphoric acid consisted of an aqueous solutionof 85 wt % of a concentrate of H₃PO₄. The mixture reacted into anamorphous phase cementitious material.

The amorphous phase cementitious material grows a plurality of crystals,each crystal having a MW of 530 generating nano-molecular elements thatproject from the plurality of crystals, encapsulating the plurality ofcrystals, wherein a majority of stabilizing material with aphosphorus-containing compound are consumed into the non-molecularveneer while increasing surface area of the plurality of crystals by49%, and wherein the nano-molecular elements of the nano-molecularveneer are insoluble in water and the nano-molecular veneer protects theplurality of crystals from degradation in water at 60 degrees Celsiusfor 24 hours forming the cementitious material.

Example 3

The cementitious material of this example has 35 wt % of a magnesiumoxide dry powder containing 80 wt % purity of magnesium oxide based on afinal total weight of the cementitious material.

The magnesium oxide used has a surface area ranging from 5 meters²/gramto 50 meters²/gram and an average particle size ranging from about 0.3to about 90 microns wherein more than about 90% by weight magnesiumoxide particles are less than or equal to about 40 microns.

15 wt % of a magnesium chloride dissolved in water based on a finaltotal weight of the cementitious material was mixed with the magnesiumoxide,

In this example, the magnesium chloride in aqueous solution was a 27 wt% a magnesium chloride aqueous solution. The magnesium oxide and themagnesium chloride in water were mixed and react to form a liquidsuspension.

2.5 wt % of a stabilizing material with a phosphorus-containing compoundbased on a final total weight of the cementitious material was mixedwith the liquid suspension, the mixture reacted into an amorphous phasecementitious material, the stabilizing material with thephosphorus-containing compound contained a phosphorous acid (A) based onthe final total weight of the cementitious material. The phosphorousacid consisted of an aqueous solution of 60 wt % of a concentrate ofH₃PO₃.

A portion of the amorphous phase cementitious material grew a pluralityof crystals, developed with each crystal having a MW of 283, 413, 530,or 709, generating nano-molecular elements that projected from theplurality of crystals, encapsulating the plurality of crystals.

A majority of phosphorous-containing compounds from the stabilizingmaterial with a phosphorus-containing compound were consumed into thenon-molecular veneer while increasing surface area of the plurality ofcrystals by 2 to 49%.

The nano-molecular elements of the nano-molecular veneer were insolublein water and the nano-molecular veneer protected the plurality ofcrystals from degradation in water at 60 degrees Celsius for 24 hours asthe cementitious material.

FIGS. 3A-3H show many samples of the formulation of the cementitiousmaterial and their associated physical properties.

Sample 1 contains 29 wt % of a magnesium oxide dry powder based on afinal total weight of the cementitious material was used. The magnesiumoxide dry powder containing 85 wt % purity of magnesium oxide.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 14 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 1, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 0.1 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

For Sample 1, the stabilizing material with the phosphorus-containingcompound was a phosphorous acid based on the final total weight of thecementitious material, wherein the phosphorous acid consists of anaqueous solution of 60 wt % of a concentrate of H₃PO₃.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

The flowable, uncured cementitious material was then poured on a mold tocure and form a cement.

For this Sample 1, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by 2% to 20 m²/g.

The cured material of Sample 1 formed a cementitious material which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 2

Sample 2 contains 40 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of the of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 18 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 2, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 10 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

For Sample 2, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

The flowable, uncured cementitious material was then poured on a moldand cured, forming a cement.

For this Sample 2, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by 49% to 29 m²/g.

The cured material of Sample 2 formed a cementitious material which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 3

Sample 3 contains 32 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of the of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 17 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 3, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 0.1 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of cementitious material the mixed liquid suspension.

For Sample 3, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

The reinforcing component was a non-woven silica-containing mat. Thereinforcing component was 0.1 wt % based on the total final weight ofthe cementitious material.

For this Sample 3, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by 2% to 20 m²/g.

The cured material of Sample 3 formed a cementitious material which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 4

Sample 4 contains 31 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of the of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 16 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 4, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 1 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

For Sample 4, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

The reinforcing component was 2 wt % chopped silica fibers based on thetotal final weight of the cementitious material.

For this Sample 4, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by 23% to 24 m²/g.

The cured material of Sample 4 formed a cementitious material which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 5

Sample 5 contains 32.5 wt % of a magnesium oxide dry powder containing85 wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 17.5 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 5, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 1.75 wt % of astabilizing material with a phosphorus-containing compound based on afinal total weight of the cementitious material to the mixed liquidsuspension.

For Sample 5, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 5 contains 0.1 wt % of aggregate component known aswood:perlite:styrene based foam beads in a 30:8:1 ratio based on thetotal final weight of the cementitious material was added into theamorphous phase cementitious material forming a flowable concrete.

The flowable, uncured concrete was then poured on a mold and cured tomake a finished concrete.

For this Sample 5, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by more than 38% to27 m²/g.

The cured material of Sample 5 formed a cementitious material which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC.

Warm Water Stability Test as authenticated by Clemson UniversityChemical Engineering Department in 2017.

Sample 6

Sample 6 contains 33 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 18 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 6, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 2.5 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material the mixed liquid suspension.

For Sample 6, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 6 contains 30 wt % of aggregate component of wood:perlite:styrenebased foam beads in a 30:8:1 ratio based on the total final weight ofthe cementitious material was added into the amorphous phasecementitious material forming a flowable concrete.

The flowable, uncured concrete was then poured into a mold and cured tomake a finished concrete.

For this Sample 6, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by more than 49% to29 m²/g.

The cured material of Sample 6 formed a cementitious material which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 7

Sample 7 contains 33 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 19 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 7, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 3.75 wt % of astabilizing material with a phosphorus-containing compound based on afinal total weight of the cementitious material to the mixed liquidsuspension.

For Sample 7, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 7 contains a biomass of 0.1 weight percent based on the totalfinal weight of the cementitious material. The biomass of this samplewas rice husks.

For this Sample 7, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by 49% to 29 m²/g.

The cured material of Sample 7 formed a cementitious material which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 8

Sample 8 contains 32 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 17 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 7, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 5 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

For Sample 8, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 8 contains 15 wt % of biomass based on the total final weight ofthe cementitious material was added into the amorphous phasecementitious material forming a flowable concrete. The biomass was cornhusks.

The flowable, uncured concrete was then poured into a mold, the finishedmaterial forming a concrete.

For this Sample 8, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by more than 44% to28 m²/g.

The cured material of Sample 8 formed a cementitious material which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 9

Sample 9 contains 35 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 16 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 9, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 6.25 wt % of astabilizing material with a phosphorus-containing compound based on afinal total weight of the cementitious material to the mixed liquidsuspension.

For Sample 9, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

0.1 weight percent of a surfactant, namely a detergent was added to theamorphous phase cementitious material based on the final total weight ofthe cementitious material.

The flowable, uncured concrete was then poured into a mold forming afinished concrete.

For this Sample 9, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by 23% to 24 m²/g.

The cured material of Sample 9 formed a cementitious material which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 10

Sample 10 contains 30 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 18 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 10, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 7.5 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

For Sample 10, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 10 contains 10 wt % of sodium stearate as a surfactant, based onthe total final weight of the cementitious material was added into theamorphous phase cementitious material forming a flowable concrete.

The flowable, uncured concrete was then poured in a mold forming afinished concrete.

For this Sample 10, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by more than 38% to27 m²/g.

The cured material of Sample 10 formed a cementitious material which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 11

Sample 11 contains 33 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 15 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 11, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 8.75 wt % of astabilizing material with a phosphorus-containing compound based on afinal total weight of the cementitious material to the mixed liquidsuspension.

For Sample 11, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

0.1 weight percent of re-dispersible polymer, namely vinyl acetateethylene (VAE) was added to the amorphous phase cementitious materialbased on the final total weight of the cementitious material.

The flowable, uncured concrete was then poured into a mold forming afinished concrete.

For this Sample 11, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by more than 49% to29 m²/g.

The cured material of Sample 11 formed a cementitious material which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 12

Sample 12 contains 32 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 19 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 12, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 10 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

For Sample 12, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 12 contains 5 wt % of vinyl acetate ethylene based on the totalfinal weight of the cementitious material was added into the amorphousphase cementitious material forming a flowable concrete.

The flowable, uncured concrete was then poured into a mold formingfinished concrete.

For this Sample 12, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by 49% to 29 m²/g.

The cured material of Sample 12 formed a cementitious material which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Example 4

A process to make a cementitious construction tile backer board follows:

The process produces a tile backer board with a 78% crystallized portionwith 12% of an amorphous nano-molecular veneer substantially free ofcrystalline silica.

To create the tile backer board, first a gel phase is formed by blendingtogether magnesium oxide powder with a purity of 85% by weight and amagnesium chloride in a brine with density of 1.26.

The magnesium oxide is blended in a weight ratio of 2:1 with themagnesium chloride based on the total final weight of the cementitiousconstruction material.

Next, from 20 weight percent of aggregate from wood is added to the gelphase forming the amorphous phase.

To the amorphous phase, 5 weight percent of phosphoric acid is addedbased on the total final weight of the cementitious constructionmaterial.

To complete forming of the tile backer board, 65% of the amorphous phaseis crystalized by extruding the amorphous phase between two layers offiberglass on a carrier sheet. The sandwich-like material is cured at45-55 degrees C. for 12-24 hours at a relative humidity greater than 55%creating a board with a thickness of 12 mm.

A nano-molecular veneer is formed over the crystallized portion with aveneer thickness of 1 micron encapsulating the portion of thecrystallized portion without producing detectable magnesium phosphate.The nano-molecular veneer has a 30% increase in surface area as comparedto veneer-free crystallized portions.

The final crystallized portion with nano-molecular veneer is configuredto resist degradation in water having a temperature at 60 degrees C. for48 hours.

Example 5

A tile backer board is formed with 70 wt % cementitious material.

The cementitious material has 34 wt % of a magnesium oxide dry powdercontaining 85 wt % purity of magnesium oxide based on a final totalweight of the cementitious material.

The magnesium oxide used has a surface area ranging from 5 meters²/gramto 50 meters²/gram and an average particle size ranging from about 0.3to about 90 microns wherein more than about 90% by weight magnesiumoxide particles are less than or equal to about 40 microns.

16 wt % of a magnesium chloride was dissolved in water based on a finaltotal weight of the cementitious material. The magnesium chloride inaqueous solution was: 29 wt % of a magnesium chloride aqueous solution.The magnesium oxide and the magnesium chloride in water, reacted to forma liquid suspension.

1.3 wt % of a stabilizing material with a phosphorus-containing compoundbased on a final total weight of the cementitious material was thenmixed with the liquid suspension and the mixture reacted into anamorphous phase cementitious material.

The stabilizing material with the phosphorus-containing compound wasphosphoric acid (B) based on the final total weight of the cementitiousmaterial, wherein the phosphoric acid consisted of an aqueous solutionof 85 wt % of a concentrate of H₃PO₄. The mixture reacted into anamorphous phase cementitious material.

Next 14 wt % of an aggregate with particles having a diameter from 1 nmto 10 mm was added to the amorphous phase cementitious material.

The aggregate contained perlite.

Additionally, 1.5 wt % of a reinforcing material based on the totalweight of the formed tile backer board was used.

The reinforcing material was a woven silica containing mat.

The amorphous phase cementitious material containing aggregate waspoured over the reinforcing material enabling a portion of the amorphousphase cementitious material to grow a plurality of crystals, eachcrystal having a MW of 530 generating nano-molecular elements thatproject from the plurality of crystals, encapsulating the plurality ofcrystals, wherein a majority of stabilizing material with aphosphorus-containing compound are consumed into the non-molecularveneer while increasing surface area of the plurality of crystals by49%, and wherein the nano-molecular elements of the nano-molecularveneer are insoluble in water and the nano-molecular veneer protects theplurality of crystals from degradation in water at 60 degrees Celsiusfor 24 hours forming the tile backer board.

Example 6

A tile backer board was formed using 65 wt % cementitious material.

The cementitious material has 35 wt % of a magnesium oxide dry powdercontaining 80 wt % purity of magnesium oxide based on a final totalweight of the cementitious material.

The magnesium oxide used has a surface area ranging from 5 meters²/gramto 50 meters²/gram and an average particle size ranging from about 0.3to about 90 microns wherein more than about 90% by weight magnesiumoxide particles are less than or equal to about 40 microns.

15 wt % of a magnesium chloride dissolved in water based on a finaltotal weight of the cementitious material was mixed with the magnesiumoxide,

In this example, the magnesium chloride in aqueous solution was a 27 wt% a magnesium chloride aqueous solution. The magnesium oxide and themagnesium chloride in water, were mixed and react to form a liquidsuspension.

2.5 wt % of a stabilizing material with a phosphorus-containing compoundbased on a final total weight of the cementitious material was mixedwith the liquid suspension, the mixture reacted into an amorphous phasecementitious material, the stabilizing material with thephosphorus-containing compound contained a phosphorous acid (A) based onthe final total weight of the cementitious material. The phosphorousacid consisted of an aqueous solution of 60 wt % of a concentrate ofH₃PO₃.

To the amorphous phase cementitious material was added 12 wt % of anaggregate with particles having a diameter from 1 nm to 10 mm. Theaggregate was a mixture of styrene based foam beads and calciumcarbonate powder.

Additionally, 7 wt % of a reinforcing material based on the total weightof the formed tile backer board was added with the aggregate. Thereinforcing material contained chopped silica containing fibers; hempcontaining fibers; nano-molecular carbon fiber strands; chopped carbonfibers; and chopped hydrocarbon fiber; in a 1:1:1:1:1 parts to eachother.

After the aggregate was added a portion of the amorphous phasecementitious material a plurality of crystals developed with eachcrystal having a MW of 283, 413, 530, or 709, generating nano-molecularelements that projected from the plurality of crystals, encapsulatingthe plurality of crystals.

A majority of phosphorous-containing compounds from the stabilizingmaterial with a phosphorus-containing compound were consumed into thenon-molecular veneer while increasing surface area of the plurality ofcrystals by 2 to 49%.

The nano-molecular elements of the nano-molecular veneer were insolublein water and the nano-molecular veneer protected the plurality ofcrystals from degradation in water at 60 degrees Celsius for 24 hours asthe tile backer board.

FIGS. 3I-3T show many samples of the formulation of the tile backerboard and their associated physical properties.

Sample 1 (this reference to “Sample 1” and the following “Sample”references refer to one of FIGS. 3I-3T) contains 29 wt % of a magnesiumoxide dry powder based on a final total weight of the cementitiousmaterial was used. The magnesium oxide dry powder containing 85 wt %purity of magnesium oxide.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 14 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 1, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 0.1 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

For Sample 1, the stabilizing material with the phosphorus-containingcompound was a phosphorous acid based on the final total weight of thecementitious material, wherein the phosphorous acid consists of anaqueous solution of 60 wt % of a concentrate of H₃PO₃.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 1 contains 0.1 wt % of aggregate component known as wood (fibers)based on the total final weight of the tile backer board was added intothe amorphous phase cementitious material forming a flowable concrete.

The flowable, uncured concrete was then poured over a reinforcingcomponent forming a reinforced concrete.

The reinforcing component was a non-woven silica containing mat thatweighed 0.1 wt % based on the total final weight of the formed tilebacker board.

For this Sample 1, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by 2% to 20 m²/g.

The cured material of Sample 1 formed a tile backer board which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 2

Sample 2 contains 40 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of the of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 18 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 2, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 10 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the tile backer board to the mixed liquid suspension.

For Sample 2, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 2 contains 30 wt % of aggregate component known as wood (fibers)based on the total final weight of the tile backer board was added intothe amorphous phase cementitious material forming a flowable concrete.

The flowable, uncured concrete was then poured over a reinforcingcomponent forming a reinforced concrete.

The reinforcing component was a woven silica containing mat. Thereinforcing component was 2 wt % based on the total final weight of thetile backer board.

For this Sample 2, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by 49% to 29 m²/g

The cured material of Sample 2 formed a tile backer board which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 3

Sample 3 contains 32 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of the of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 17 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 3, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 0.1 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of cementitious material the mixed liquid suspension.

For Sample 3, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 3 contains 15 wt % of aggregate component known as perlite basedon the total final weight of the tile backer board was added into theamorphous phase cementitious material forming a flowable concrete.

0.1 weight percent of a biomass known as rice husks was added to theamorphous phase cementitious material based on the final total weight ofthe tile backer board.

The flowable, uncured concrete was then poured over a reinforcingcomponent forming a reinforced concrete.

The reinforcing component was a non-woven hydrocarbon-containing mat.The reinforcing component was 0.1 wt % based on the total final weightof the tile backer board.

For this Sample 3, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by 2% to 20 m²/g.

The cured material of Sample 3 formed a tile backer board which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 4

Sample 4 contains 31 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of the of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 16 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 4, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 1 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

For Sample 4, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 4 contains 15 wt % of aggregate component known as perlite basedon the total final weight of the tile backer board was added into theamorphous phase cementitious material forming a flowable concrete.

15 weight percent of a biomass known as corn husks was added to theamorphous phase cementitious material based on the final total weight ofthe tile backer board.

The flowable, uncured concrete was then poured over a reinforcingcomponent forming a reinforced concrete.

The reinforcing component was a woven hydrocarbon-containing mat. Thereinforcing component was 0.1 wt % based on the total final weight ofthe cementitious material.

For this Sample 4, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by 23% to 24 m²/g.

The cured material of Sample 4 formed a tile backer board which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 5

Sample 5 contains 32.5 wt % of a magnesium oxide dry powder containing85 wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 17.5 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 5, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 1.75 wt % of astabilizing material with a phosphorus-containing compound based on afinal total weight of the cementitious material to the mixed liquidsuspension.

For Sample 5, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 5 contains 15 wt % of aggregate component known as styrene basedfoam beads based on the total final weight of the tile backer board wasadded into the amorphous phase cementitious material forming a flowableconcrete.

Sample 5 contains 0.1 wt % detergent as a surfactant based on the totalfinal weight of the tile backer board which is added to the amorphousphase cementitious material to decrease porosity of aggregate andprevent amorphous phase cementitious material from entering pores of theaggregate.

Sample 5 contains 1 wt % chopped silica containing fibers based on thetotal final weight of the tile backer board.

The flowable, uncured concrete was then poured over a reinforcingcomponent forming a reinforced concrete.

The reinforcing component was a non-woven silica containing mat. Thereinforcing component was 0.1 wt % based on the total final weight ofthe tile backer board.

For this Sample 5, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by more than 38% to27 m²/g.

The cured material of Sample 5 formed a tile backer board which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC. Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 6

Sample 6 contains 33 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 18 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 6, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 2.5 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material the mixed liquid suspension.

For Sample 6, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 6 contains 15 wt % of aggregate component known as glassparticulate based on the total final weight of the tile backer board wasadded into the amorphous phase cementitious material forming a flowableconcrete.

Sample 6 contains 10 wt % sodium stearate as a surfactant based on thetotal final weight of the tile backer board which is added to theamorphous phase cementitious material to decrease porosity of aggregateand prevent amorphous phase cementitious material from entering pores ofthe aggregate.

Sample 6 contains 10 wt % chopped silica containing fibers based on thetotal final weight of the tile backer board.

The flowable, uncured concrete was then poured over a reinforcingcomponent forming a reinforced concrete.

The reinforcing component was a woven silica containing mat. Thereinforcing component was 0.1 wt % based on the total final weight ofthe tile backer board.

For this Sample 6, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by more than 49% to29 m²/g.

The cured material of Sample 6 formed a tile backer board which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 7

Sample 7 contains 33 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 19 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 7, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 3.75 wt % of astabilizing material with a phosphorus-containing compound based on afinal total weight of the cementitious material to the mixed liquidsuspension.

For Sample 7, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 7 contains 11 wt % of aggregate component as a ratio of 30:8:1 ofwood, perlite, and styrene foam beams based on the total final weight ofthe tile backer board was added into the amorphous phase cementitiousmaterial forming a flowable concrete.

0.1 weight percent of a re-dispersible powder polymer was added to theamorphous phase cementitious material based on the final total weight ofthe tile backer board. The re-dispersible powder polymer was a vinylacetate ethylene.

The flowable, uncured concrete was then poured over a reinforcingcomponent forming a reinforced concrete.

The reinforcing component was a woven hydrocarbon containing mat. Thereinforcing component was 0.1 wt % based on the total final weight ofthe tile backer board.

For this Sample 7, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by 49% to 29 m²/g.

The cured material of Sample 7 formed a tile backer board which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 8

Sample 8 contains 32 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 17 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 7, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 5 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

For Sample 8, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 8 contains 12 wt % of aggregate component as a ratio of 30:8:1 ofwood, perlite, and styrene foam beams based on the total final weight ofthe tile backer board was added into the amorphous phase cementitiousmaterial forming a flowable concrete.

5 weight percent of a re-dispersible powder polymer was added to theamorphous phase cementitious material based on the final total weight ofthe tile backer board. The re-dispersible powder polymer was a vinylacetate ethylene.

The flowable, uncured concrete was then poured over a reinforcingcomponent forming a reinforced concrete.

The reinforcing component was a non-woven silica containing mat. Thereinforcing component was 0.1 wt % based on the total final weight ofthe tile backer board.

For this Sample 8, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by more than 44% to28 m²/g.

The cured material of Sample 8 formed a tile backer board which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 9

Sample 9 contains 35 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 16 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 9, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 6.25 wt % of astabilizing material with a phosphorus-containing compound based on afinal total weight of the cementitious material to the mixed liquidsuspension.

For Sample 9, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 9 contains 13 wt % of aggregate component as a ratio of 30:8:1 ofwood, perlite, and styrene foam beams based on the total final weight ofthe tile backer board was added into the amorphous phase cementitiousmaterial forming a flowable concrete.

0.1 weight percent of an acrylic was added to the amorphous phasecementitious material based on the final total weight of the tile backerboard.

The flowable, uncured concrete was then poured over a reinforcingcomponent forming a reinforced concrete.

The reinforcing component was a woven silica containing mat. Thereinforcing component was 0.1 wt % based on the total final weight ofthe tile backer board.

For this Sample 9, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by 23% to 24 m²/g.

The cured material of Sample 9 formed a tile backer board which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 10

Sample 10 contains 30 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 18 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 10, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 7.5 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

For Sample 10, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 10 contains 14 wt % of aggregate component as a ratio of 30:8:1of wood, perlite, and styrene foam beams based on the total final weightof the tile backer board was added into the amorphous phase cementitiousmaterial forming a flowable concrete.

5 weight percent of an acrylic was added to the amorphous phasecementitious material based on the final total weight of the tile backerboard.

The flowable, uncured concrete was then poured over a reinforcingcomponent forming a reinforced concrete.

The reinforcing component was a woven hydrocarbon containing mat. Thereinforcing component was 0.1 wt % based on the total final weight ofthe tile backer board.

For this Sample 10, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by more than 38% to27 m²/g.

The cured material of Sample 10 formed a tile backer board which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 11

Sample 11 contains 33 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 15 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 11, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 8.75 wt % of astabilizing material with a phosphorus-containing compound based on afinal total weight of the cementitious material to the mixed liquidsuspension.

For Sample 11, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 11 contains 16 wt % of aggregate component as a ratio of 30:8:1of wood, perlite, and styrene foam beams based on the total final weightof the tile backer board was added into the amorphous phase cementitiousmaterial forming a flowable concrete.

0.1 weight percent of a styrene butadiene rubber was added to theamorphous phase cementitious material based on the final total weight ofthe tile backer board.

The flowable, uncured concrete was then poured over a reinforcingcomponent forming a reinforced concrete.

The reinforcing component was a non-woven silica containing mat. Thereinforcing component was 0.1 wt % based on the total final weight ofthe tile backer board.

For this Sample 11, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by more than 49% to29 m²/g.

The cured material of Sample 11 formed a tile backer board which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 12

Sample 12 contains 32 wt % of a magnesium oxide dry powder containing 85wt % of magnesium oxide based on a final total weight of thecementitious material was used.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 19 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 12, the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water form a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 10 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

For Sample 12, the stabilizing material with the phosphorus-containingcompound was a phosphoric acid based on the final total weight of thecementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 2minutes.

Sample 12 contains 17 wt % of aggregate component as a ratio of 30:8:1of wood, perlite, and styrene foam beams based on the total final weightof the tile backer board was added into the amorphous phase cementitiousmaterial forming a flowable concrete.

5 weight percent of a styrene butadiene rubber was added to theamorphous phase cementitious material based on the final total weight ofthe tile backer board.

The flowable, uncured concrete was then poured over a reinforcingcomponent forming a reinforced concrete.

The reinforcing component was a woven silica containing mat. Thereinforcing component was 0.1 wt % based on the total final weight ofthe tile backer board.

For this Sample 12, a portion of the amorphous phase cementitiousmaterial formed a plurality of crystals, each crystal is known as a“Magnesium Oxychloride Cement Crystals” having a MW of 530.7 withamorphous non-crystalline nano-molecular cementitious materialencapsulating the plurality of crystals, creating a nano-molecularveneer without detectable phosphorus-containing compound whileincreasing surface area of the plurality of crystals by 49% to 29 m²/g.

The cured material of Sample 12 formed a tile backer board which asstable in water at 60 degrees Celsius for 24 hours using the JetProducts, LLC Warm Water Stability Test as authenticated by ClemsonUniversity Chemical Engineering Department in 2017.

Sample 13

Sample 13 has 29 wt % of a magnesium oxide dry powder containing 85 wt %of magnesium oxide based on a final total weight of the cementitiousmaterial.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 14 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 13 the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water formed a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 0.1 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

For Sample 13 the stabilizing material with the phosphorus-containingcompound was a phosphorous acid (A) based on the final total weight ofthe cementitious material, wherein the phosphorous acid consists of anaqueous solution of 60 wt % of a concentrate of H₃PO₃.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 3minutes.

Next, to form the tile backer board of this Sample 13, 0.1 wt % ofaggregate component known as wood fibers based on the total final weightof the tile backer board was added into the amorphous phase cementitiousmaterial forming a flowable concrete.

The flowable, uncured concrete was then mixed with a reinforcingcomponent forming a reinforced concrete.

The reinforcing component was 0.1 wt percent chopped silica containingfibers.

In this sample, a portion of the amorphous phase cementitious materialforms a plurality of crystals, each crystal is known as a “MagnesiumOxychloride Cement Crystal” having a MW of 530.7 with amorphousnon-crystalline nano-molecular cementitious material encapsulating theplurality of crystals, forming a nano-molecular veneer withoutdetectable phosphorus-containing compound while increasing surface areaof the plurality of crystals by 2% to 20 m²/g.

The cured material formed a tile backer board which as stable in waterat 60 degrees Celsius for 24 hours using the Jet Products, LLC WarmWater Stability Test as authenticated by Clemson University ChemicalEngineering Department in 2017.

Sample 14

Sample 14 has 40 wt % of a magnesium oxide dry powder containing 85 wt %of magnesium oxide based on the formed cementitious material.

The magnesium oxide had a surface area ranging from 5 meters²/gram to 50meters²/gram and an average particle size ranging from about 0.3 toabout 90 microns wherein more than about 90% by weight magnesium oxideparticles were less than or equal to about 40 microns.

The magnesium oxide was blended with 18 wt % of a magnesium chloridedissolved in water based on a final total weight of the cementitiousmaterial.

For Sample 14 the magnesium chloride in aqueous solution was a 28 wt %magnesium chloride aqueous solution.

After 3 minutes of mixing with a planetary mixer, the magnesium oxideand the magnesium chloride in water formed a liquid suspension whileminimizing adding gas into the liquid suspension.

For this sample, the next step involved adding 0 wt % of a stabilizingmaterial with a phosphorus-containing compound based on a final totalweight of the cementitious material to the mixed liquid suspension.

For Sample 14 the stabilizing material with the phosphorus-containingcompound was was a phosphoric acid based on the final total weight ofthe cementitious material, wherein the phosphoric acid consists of anaqueous solution of 80 wt % to 90 wt % of a concentrate of H₃PO₄.

The liquid suspension with stabilizing material was permitted to reactinto an amorphous phase cementitious material for a period of time of 3minutes.

Next, to form the tile backer board of this Sample 14, 30 wt % ofaggregate component known as wood fibers based on the total final weightof the tile backer board was added into the amorphous phase cementitiousmaterial forming a flowable concrete.

The flowable, uncured concrete was then mixed with a reinforcingcomponent forming a reinforced concrete.

The reinforcing component was 15 wt percent nano-molecular carbon fiberstrands.

In this sample, a portion of the amorphous phase cementitious materialforms a plurality of crystals, each crystal is known as a “MagnesiumOxychloride Cement Crystal” having a MW of 530.7 with amorphousnon-crystalline nano-molecular cementitious material encapsulating theplurality of crystals, forming a nano-molecular veneer withoutdetectable phosphorus-containing compound while increasing surface areaof the plurality of crystals by 49% to 29 m²/g.

The cured material formed a tile backer board which as stable in waterat 60 degrees Celsius for 24 hours using the Jet Products, LLC WarmWater Stability Test as authenticated by Clemson University ChemicalEngineering Department in 2017.

FIGS. 3P-3T also show samples 15 to 24 present additional formulationsand physical properties of created tile backer board samples usingchopped fibers as the reinforcing component and different additives,including biomass, surfactant, re-dispersible polymer power, acrylic andstyrene butadiene rubber which were created in the manner identical toSamples 1 to 14.

FIG. 4 shows a first example of a magnesium oxychloride cement boardusing U.S. raw materials and 0% phosphoric acid.

FIG. 4 shows a second example of a magnesium oxychloride cement boardusing U.S. raw materials and 1.25% phosphoric acid.

FIG. 4 shows a third example of a magnesium oxychloride cement boardusing U.S. raw materials and 2.5% phosphoric acid.

FIG. 4 shows a fourth example of a magnesium oxychloride cement boardusing Chinese raw materials and 0% phosphoric acid.

FIG. 4 shows a fifth example of a magnesium oxychloride cement boardusing Chinese raw materials and 1.5% phosphoric acid.

FIG. 4 shows a sixth example of a magnesium oxychloride cement boardusing Chinese raw materials and 3% phosphoric acid.

The invention claimed is:
 1. A cementitious material comprisingmagnesium oxychloride crystals at least partially surrounded by aphosphorus-containing amorphous layer, wherein the magnesium oxychloridecrystals constitute from about 45 wt % to about 85 wt % of thecementitious material, as determined by X-Ray Diffraction.
 2. Thecementitious material of claim 1, wherein the phosphorus-containingamorphous layer is substantially free of crystalline silica.
 3. Thecementitious material of claim 2, wherein the phosphorus-containingamorphous layer is in the form of a nano-molecular veneer comprisingnon-crystalline, phosphorus-containing species identifiable by elementalanalysis utilizing a scanning electron microscope (SEM).
 4. Thecementitious material of claim 3, wherein at least a portion of thenano-molecular veneer is insoluble in water.
 5. The cementitiousmaterial of claim 1, wherein the cementitious material is characterizedby one or more of the following: (i) from 10 wt % to about 50 wt % ofthe phosphorus-containing amorphous layer, as determined by X-RayDiffraction; and/or (ii) a magnesium oxychloride crystal content, aftera 24 hour soak in water having a temperature of 60° C., of from about 2wt % to about 50 wt %, as determined by X-Ray Diffraction; and/or (iii)a BET surface area of from about 20 m²/g to about 30 m²/g.
 6. Thecementitious material of claim 1, wherein the cementitious material issubstantially free of magnesium phosphate.
 7. The cementitious materialof claim 1, the material further comprising from 0.1 wt % to 30 wt % ofaggregate based on the total weight of the material.
 8. The cementitiousmaterial of claim 7, wherein the aggregate is selected from the groupconsisting of wood, perlite, styrene based foam beads, calcium carbonatepowder, glass particulate, and combinations thereof.
 9. The cementitiousmaterial of claim 1, the material further comprising from 0.1 wt % to 2wt % of a reinforcing material based on the total weight of thematerial.
 10. The cementitious material of claim 9, wherein thereinforcing material is selected from the group consisting of non-wovensilica containing mat, woven silica-containing mat, non-wovenhydrocarbon containing wat, woven hydrocarbon containing mat, andcombinations thereof.
 11. The cementitious material of claim 1, thematerial further comprising from 0.1 wt % to 15 wt % of biomass based onthe total weight of the material.
 12. The cementitious material of claim11, wherein the biomass is selected from the group consisting of ricehusks, corn husks, dung, and combinations thereof.
 13. The cementitiousmaterial of claim 1, the material further comprising from 0.1 wt % to 10wt % of at least one surfactant based on the total weight of thematerial.
 14. The cementitious material of claim 1, the material furthercomprising from 0.1 wt % to 5 wt % of a re-dispersible powder polymerbased on the final total weight of the material.
 15. The cementitiousmaterial of claim 14, wherein the re-dispersible powder is selected fromthe group consisting of silicon, polyurethane dispersion, polyurethane,alkyl carboxylic acid vinyl ester monomer, branched and unbranchedalcohol(meth)acrylic acid ester monomer, vinyl aromatic monomer, olefinmonomer, diene monomer, vinyl halide monomer, vinyl acetate ethylene(VAE), and combinations thereof.
 16. The cementitious material of claim1, the material further comprising from 0.1 wt % to 5 wt % of an acrylicor styrene butadiene rubber (SBR) based on the total final weight of thematerial.
 17. The cementitious material of claim 1, the material furthercomprising from 0.1 wt % to 15 wt % of a reinforcing material based onthe total weight of the material.
 18. The cementitious material of claim17, wherein the reinforcing material is selected from the groupconsisting of chopped silica containing fibers, hemp containing fibers,nano-molecular carbon fiber strands, chopped carbon fibers, choppedhydrocarbon fibers, and combinations thereof.
 19. The cementitiousmaterial of claim 1, wherein the cementitious material is characterizedby from 10 wt % to about 50 wt % of the phosphorus-containing amorphouslayer, as determined by X-Ray Diffraction.
 20. The cementitious materialof claim 1, wherein the cementitious material is characterized by amagnesium oxychloride crystal content, after a 24 hour soak in waterhaving a temperature of 60° C., of from about 2 wt % to about 50 wt %,as determined by X-Ray Diffraction.
 21. The cementitious material ofclaim 1, wherein the cementitious material is characterized by a BETsurface area of from about 20 m²/g to about 30 m²/g.
 22. A cementitiousconstruction material, the construction material comprising cementitiousmaterial comprising magnesium oxychloride crystals at least partiallysurrounded by a phosphorus-containing amorphous layer, wherein themagnesium oxychloride crystals constitute from about 45 wt % to about 85wt % of the cementitious material, as determined by X-Ray Diffraction.23. A tile backer board, the tile backer board comprising cementitiousmaterial comprising magnesium oxychloride crystals at least partiallysurrounded by a phosphorus-containing amorphous layer, wherein themagnesium oxychloride crystals constitute from about 45 wt % to about 85wt % of the cementitious material, as determined by X-Ray Diffraction.